projekt zeal86 (build thread)

[Clipdat]

I mean this in the nicest way possible, but why the fuck haven't you ordered this yet?

http://www.ft86speedfactory.com/trd-...over-1915.html

[Scrappydoo]

When you finish the engine cover are you going to do anything with the alternator lead? They are seriously ugly.

[zeal86]

Originally Posted by Scrappydoo

When you finish the engine cover are you going to do anything with the alternator lead? They are seriously ugly.

I'm still considering covering it as part of the cover... we'll see...

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[zeal86]

This prepped door cup is a better example than my first one... more hand filing... less dremeling... lol



If I have to make any adjustments to my first door strap pull (adjustment = partial disassembly) ... I'll go ahead and file the first door cup to get cleaner edges and more even surfaces... That's the OCD in me...

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[Scrappydoo]

Originally Posted by zeal86

I'm still considering covering it as part of the cover... we'll see...

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Or some form of wrap or braiding. Just getting rid of the grey would help.

[zeal86]

So I gave my first version of my door strap pull a test drive... it was a no go... not enough swing to pull the cable... however...I removed the spring and it seems as it was the limiting factor...

I'll give it another shot later... It appears that removing the spring will do the trick... If it does...hopefully there is enough recoil from the cable to reset the door strap pull.

btw, I did go back to hand file the first door cup for cleaner edges and flatter surfaces... I couldn't help myself :p

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[zeal86]

I may need to remake the lever at a slightly more acute angle...I need a tad bit more swing. I'll bring in the long arm about 3° then cut and shape it by hand... once it is right, I'll have it cut out on a gravo cutter.



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[zeal86]

I'll be trying this version of my lever soon. I will make this next version manually out of a thicker aluminum.

4°swing inward on the long arm... also beefed up the center... (red=orig)



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[zeal86]

I haven't made my new lever yet but I decided to bring in the angle of the long arm another 3° for a total of 7°. I hope to have the new levers completed on Monday.

I'm also going to try a 1/16" stainless steel rod in place of the wire rope... we'll see how that works out. I haven't given up on the OEM spring...I'm going to give it another go with the steel rod. Also, trying to find some brake cable clamp bolts and nuts... so far I've been unlucky... I might have to go to a bike shop for those.

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[zeal86]

My coworker found me some really cool hardware today that is perfect for this application. l'll post a pic of the hardware in my future write-up because I don't know the exact name.

I'm in the middle of tinkering with a stainless steel rod instead of wire rope. I'm sure the end product will include a steel rod because it pulls and pushes stronger and smoother than the wire rope.

I'm going to make another adjustment to my lever design and I'm still trying to incorporate the spring. More to come soon...

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[zeal86]

I made some changes to my design... I had to remove the spring again as it still limits the rotation of the lever mechanism. I have one more idea to test out to see if I can keep the spring in my design. I'll test my newest changes out on Thursday...

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Riveted the two pieces together so I could shape them together... turned out decent. These levers are made from a thicker aluminum than my previous one.







Sourced a cool little swivel cable stop for this project...





I installed a cotter key to let the pull strap to move more freely...





stay tuned... more to come...

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[zeal86]

Well...trial and error has gotten me to this point. Stumbled across some hardware that is perfect for this application... Its called a throttle swivel. I drilled a maintenance hole so I can tighten the set screw on the throttle swivel.

At this point I don't think I'll try to make the OEM spring work... I think that the cable will have enough retraction to reset the handle to neutral. I'll test this out soon... I have a good feeling it will work though. Detailed write-up coming soon.













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[shadow_772]

Progress is looking good!

[zeal86]

Door cup covers made... will be upholstered soon with the same suede I covered my rear seat delete with...



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